Vehicle door handle apparatus and two-shot injection molding process for producing components with a metallic surface finish

ABSTRACT

A vehicle door handle apparatus is disclosed that generally includes a structural core and an outer layer. The structural core has an outer surface, a base portion, and a handle portion that extends from the base portion. The outer layer extends about and covers the outer surface of at least the handle portion of the structural core. The structural core is made of a first material that contains an engineering thermoplastic and glass fibers for reinforcement. The outer layer is made of a second material that contains the engineering thermoplastic and a milled material to give the outer layer a metallic surface finish. Non-limiting examples of the engineering thermoplastic are polyoxymethylene and polybutylene terephthalate. A method is also disclosed for producing an injection molded component having a metallic surface finish such as the disclosed vehicle door handle apparatus.

RELATED APPLICATIONS

This application is a divisional application of U.S. Ser. No.14/724,190, filed May 28, 2015.

FIELD

The subject disclosure relates o injection molded components that have ametallic surface finish such as vehicle door handles and to methods forproducing the same.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Injection molded components are widely used in the automotive industryfor various trim pieces and other parts that are installed both insideand outside a vehicle. Such injection molded components are typicallymade of a thermoplastic material. Typically, injection molded componentsare lighter and cheaper to make in comparison to metal parts,particularly when the part requires complex shapes and curves. Injectionmolded components also tend to be more corrosion resistant than metalparts, which are prone to rust. However, consumers typically associateinjection molded components with inferior quality largely due to theirweight and appearance. Accordingly, there has been a trend within theautomotive industry in recent years to improve the quality of injectionmolded components, including making improvements to the appearance ofthese components. This is especially true within luxury brands andvehicles with upgraded trim packages. These advances have led to theproliferation of injection molded components that simulate (i.e. havethe appearance of) metal parts.

One area where improvements in injection molded components are notableis in vehicle door handles on both the inside and outside of thevehicle. At one time, vehicle door handles were commonly made of metal.Due to cost reduction efforts, most vehicle door handles are now made ofplastic using injection molding processes. While this change givesautomakers more options regarding the shape of the door handle, standardinjection molded components have a dull surface finish and are oftenperceived by consumers as having a “cheap” appearance. One way thatautomakers have “dressed-up” the appearance of these injection moldedcomponents is by chrome plating vehicle door handles. Examples ofchrome-plated vehicle door handles are found in U.S. Pat. No. 7,544,319entitled “Vehicle Handle Assembly With Antenna,” which issued to Marchet al. on Jun. 9, 2009 and Canadian Patent Application No. 2,047,625entitled “Injection Molding Process For Platable Plastic Substrates,”which was published on Jan. 25, 1992 naming Robert L. Coombes, Jr. asthe inventor. Both of these references teach vehicle door handles thatare manufactured using a conventional two-shot injection moldingprocess. The vehicle door handles have two plastic layers, an innerlayer that is formed by the first shot and an outer layer that is formedby the second shot. Both references explicitly call for the outer layerto be made of a platable plastic material. In other words, the plasticmaterial forming the outer layer is selected from a group of plasticsthat are compatible with the chrome plating process(i.e. plastics thatchrome can adhere to). Chrome plating is applied to the platable plasticmaterial to create a vehicle door handle that ultimately includes threelayers—two plastic layers and one layer of chrome plate. As explained inthe references, the chrome plating can be applied by immersing at leastpart of the vehicle door handle in one or more electroplating baths,where metal is electrolytically deposited on the surface of the outerlayer. This is a fairly lengthy and expensive manufacturing processbecause the vehicle door handle is not a finished component when it isremoved from the mold. Also, the chemicals used in the chrome platingprocess are hazardous to the environment and can create adverse healtheffects when exposed to humans. Therefore, caution must be used in thehandling and disposal of these chemicals.

Although the chrome plated vehicle door handles produced by this processhave a metallic appearance and are thus more aesthetically pleasing thanun-plated injection molded door handles, they suffer from a number ofproblems in addition to the time, expense, and environmental drawbacksthat are associated with the chrome plating process. First, the metalthat is deposited on the outer layer of the vehicle door handle issusceptible to corrosion. As such, the chrome plating itself may rusteven if the plastic material forming the inner and outer layers cannot.Second, the chrome plating can bubble, peel, and chip. This not onlydetracts from the appearance of the vehicle door handle, but the exposededges of the chrome plating tend to be sharp and can cut a person's handwhen they grab the vehicle door handle during ingress or egress. What isneeded is an alternative solution to chrome plating that produces aplastic vehicle door handle with a metallic surface finish at areasonable cost.

SUMMARY

This section provides a general summary of the disclosure and is not acomprehensive disclosure of its full scope or all of its features.

In accordance with one aspect of the subject disclosure, a vehicle doorhandle apparatus is provided. The vehicle door handle apparatusgenerally includes a structural core and an outer layer. The structuralcore has a base portion with at least one mounting feature and a handleportion that extends from the base portion. The structural core also hasan outer surface that extends along both the base portion and the handleportion. The outer layer of the vehicle handle apparatus extends aboutand covers the outer surface of at least the handle portion of thestructural core. The structural core is made of a first material thatcontains an engineering thermoplastic and glass fibers forreinforcement. The outer layer is made of a second material thatcontains the engineering thermoplastic and a milled material to give theouter layer a metallic surface finish.

In accordance with another aspect of the subject disclosure, a methodfor producing an injection molded component having a metallic surfacefinish is provided. The method includes the step of heating a firstmaterial containing an engineering thermoplastic and glass fibers forreinforcement to a first temperature. The first temperature is above amelting point of the first material. The method also includes the stepof injecting a first shot of the first material into a mold cavity at afirst volumetric flowrate. The mold cavity defines a volume of theinjection molded component. In accordance with the step of injecting thefirst shot, the first volumetric flowrate ranges from 33 percent of thevolume of the injection molded component per second to 100 percent ofthe volume of the injection molded component per second. The methodincludes the step of holding a surface of the mold cavity at a secondtemperature. The second temperature is below the melting point of thefirst material. This step cools the first material that was injectedinto the mold cavity, which forms a structural core of the injectionmolded component.

The method also includes the step of heating a second materialcontaining the engineering thermoplastic and a milled material to athird temperature. The third temperature is above a melting point of thesecond material and is less than the first temperature. The methodfurther includes the step of injecting a second shot of the secondmaterial into the mold cavity between the surface of the mold cavity andthe structural core at a second volumetric flowrate. The secondvolumetric flowrate is less than the first volumetric flowrate. In otherwords, the process calls for injecting the second shot into the moldcavity at a slower rate compared to the rate at which the first shot isinjected into the mold cavity. This is done in order to avoid metamericfailure in the second material, which is caused by disrupting thedistribution and orientation of the milled material that is containedwithin the second material. In accordance with the step of injecting thesecond shot, the second volumetric flowrate ranges from 5 percent of thevolume of the injection molded component per second to 25 percent of thevolume of the injection molded component per second. The method alsoincludes the step of holding the surface of the mold cavity at a fourthtemperature. The fourth temperature is less than a melting point of thesecond material. In this step, the second material that is injected intothe mold cavity fuses with the first material of the structural core andforms an outer layer around the structural core. Accordingly, the outerlayer that is produced by this method is made of the second material andhas a uniform metallic surface finish that is provided by the milledmaterial. The method additionally includes the step of removing theinjection molded component, which comprises the structural core and theouter layer, from the mold cavity.

Advantageously, the disclosed vehicle door handle apparatus is lighter,cheaper, stronger, and less prone to buzz, squeak, and rattle (BSR) whencompared to chrome plated vehicle door handles. Consumers are alsobenefited because there is no chrome plating to rust, bubble, peel andchip. The disclosed vehicle door handle and the process for itsmanufacture thus provide a solution to the problem of chipped chromeplated handles cutting the hands of consumers. The disclosed method formanufacturing injection molded components, such as the disclosed vehicledoor handle apparatus, also allows for a composite injection moldedcomponent to be created with an outer layer that has a uniform, highluster, metallic surface finish right out of the mold. Other two-shotinjection molding processes are incapable of providing the same qualityof metallic surface finish and the disclosed method eliminates the needfor a subsequent chrome plating process. This simplifies themanufacturing process, reduces cost, and has environmental benefits overchrome plating.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated,as the same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a front perspective view of an exemplary vehicle door handleapparatus constructed in accordance with the subject invention, whichincludes a structure core and an outer layer;

FIG. 2 is a front perspective view of the structural core of theexemplary vehicle door handle apparatus illustrated in FIG. 1;

FIG. 3 is a front perspective view of the outer layer of the exemplaryvehicle door handle apparatus illustrates in FIG. 1;

FIG. 4 is an enlarged view of the outer layer of the exemplary vehicledoor handle apparatus where the outer layer is shown having a uniformmetallic surface finish that is free of metameric failures and otherdefects;

FIG. 5 is another enlarged view of the outer layer of the exemplaryvehicle door handle apparatus where the outer layer is shown withmetameric failures and flow line defects;

FIG. 6 is a flowchart illustrating the steps of the disclosed method forproducing an injection molded component having a metallic surfacefinish; and

FIG. 7 is a side cross-sectional view of an exemplary mold that isconfigured to carry out the disclosed method.

DETAILED DESCRIPTION

Referring to the Figures, wherein like numerals indicate correspondingparts throughout the several views, a vehicle door handle apparatus 20is disclosed along with a two-shot injection molding process. Thetwo-shot injection molding process involves a method for producing aninjection molded component having a metallic surface finish. Theinjection molded component that is produced by this process may be, forexample, the vehicle door handle apparatus 20.

Example embodiments will now be described more fully with reference tothe accompanying drawings. Example embodiments are provided so that thisdisclosure will be thorough, and will fully convey the scope to thosewho are skilled in the art. Numerous specific details are set forth suchas examples of specific components, devices, and methods, to provide athorough understanding of embodiments of the present disclosure. It willbe apparent to those skilled in the art that specific details need notbe employed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groups thereofThe method steps, processes, and operations described herein are not tobe construed as necessarily requiring their performance in theparticular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

With reference to FIGS. 1-3, the vehicle door handle apparatus 20 isshown in various stages of completion. FIG. 1 illustrates the vehicledoor handle apparatus 20 in a final stage of completion, where thevehicle door handle apparatus 20 is ready to be installed in or on avehicle door (not shown). The vehicle door handle apparatus 20 generallyincludes a structural core 22 and an outer layer 24. Although thevehicle door handle apparatus 20 that is illustrated in the figures isdesigned for installation on an interior side of the vehicle door (i.e.the side of the vehicle door that faces the passenger compartment of thevehicle), it should be appreciated that the subject disclosure alsoencompasses configurations of the vehicle door handle apparatus 20 thatare designed for installation on an exterior side of the vehicle door(i.e. the side of the vehicle door that is exposed to the outsideenvironment). The vehicle door handle apparatus 20 disclosed herein isgenerally used for opening and/or closing the vehicle door. FIG. 2illustrates only the structural core 22 of the vehicle door handleapparatus 20. The structural core 22 has a base portion 26 and a handleportion 28. The base portion 26 of the structural core 22 generallyincludes one or more mounting features 30. By way of example and withoutlimitation, the mounting features 30 may be holes or bores that extendthrough the base portion 26 of the structural core 22. When the vehicledoor handle apparatus 20 is installed, bolts or other fasteners (notshown)may extend through the mounting features 30 to couple the vehicledoor handle apparatus 20 to the vehicle door and/or to one or morelinkages that effectuate the release of a vehicle door latch mechanism(not shown).

The handle portion 28 of the structural core 22 generally extends fromthe base portion 26. The handle portion 28 of the structural core 22 mayextend in one or more directions outwardly from the base portion 26 suchthat the handle portion 28 may be straight or curved. The handle portion28 is thus configured to be grasped by a person's hand or portionsthereof (such as one or more fingers) and be pushed, pulled, slid, orrotated to effectuate the release of the vehicle door latch mechanism.Accordingly, the distance that the handle portion 28 extends should beselected with these ergonomic requirements in mind. The structural core22 has an outer surface 32 that extends along both the base portion 26and the handle portion 28. The outer surface 32 generally includes afront face 34 and a rear face 36. The rear face 36 is oppositelydirected with respect to the front face 34. Where the vehicle doorhandle apparatus 20 is installed on the interior side of the vehicledoor, the front face 34 generally faces the passenger compartment of thevehicle and the rear face 36 generally faces the interior side of thevehicle door. Where the vehicle door handle apparatus 20 is installed onthe exterior side of the vehicle door, the front face 34 generally facesthe outside environment (i.e. away from the vehicle) and the rear face36 generally faces the exterior side of the vehicle door.

As shown in FIG. 1, the outer layer 24 of the vehicle door handleapparatus 20 generally extends about and covers the outer surface 32 ofat least the handle portion 28 of the structural core 22. As such, itshould be appreciated that the outer layer 24 covers both the front andrear faces 34, 36 of the outer surface 32 at or along the handle portion28. FIG. 3 shows the outer layer 24 of the vehicle door handle apparatus20 in isolation from the structural core 22 for illustration purposes,although it should be appreciated that the outer layer 24 may be fusedwith the structural layer such that removal of the outer layer 24 fromthe structural core 22 may not in fact be feasible. From FIGS. 1-3, itshould be appreciated that the outer layer 24 extends continuously aboutat least the handle portion 28 of the structural core 22 and isrelatively thin in comparison to the structural core 22. In accordancewith one aspect of the subject disclosure, the outer layer 24 may have anominal thickness 38 (i.e. average thickness) ranging from 0.5millimeters (mm) to 3.0 millimeters (mm).

The structural core 22 of the vehicle door handle apparatus 20 is madeof a first material 40 that contains an engineering thermoplastic andglass fibers for reinforcement. It should be appreciated that the term“engineering thermoplastic” is an industry recognized term that refersto a group of plastic materials that have better mechanical properties,thermal properties, chemical resistance, and/or ultra-violet resistancethan more widely used commodity plastics. By way of non-limitingexample, engineering thermoplastics include: acrylonitrile butadienestyrene (ABS), polycaprolactam (Nylon 6), polyamides (PA), polybutyleneterephthalate (PBT), polycarbonates (PC), polyetheretherketone (PEEK),polyetherketone (PEK), polyethylene terephthalate (PET), polyimides,polyoxymethylene plastic (POM), polyphenylene sulfide (PPS),polyphenylene oxide (PPO), polysulphone (PSU), and ultra-high molecularweight polyethylene (UHMWPE). In accordance with one aspect of thesubject disclosure, the first material 40 (i.e. the material used forthe structural core 22) is a glass reinforced polyoxymethylene (POM).This engineering thermoplastic has been found to be particularlysuitable where the vehicle door handle apparatus 20 is intended to beinstalled on the interior side of the vehicle door. In accordance withanother aspect of the subject disclosure, the first material 40 (i.e.the material used for the structural core 22) is a glass reinforcedpolybutylene terephthalate (PBT). This engineering thermoplastic hasbeen found to be particularly suitable where the vehicle door handleapparatus 20 is intended to be installed on the exterior side of thevehicle door. The first material 40 gives the outer surface 32 of thestructural core 22 a dull surface finish, meaning that the outer surface32 of the structural core 22 is not highly reflective (i.e. is notshiny). Accordingly, the outer surface 32 of the structural core 22 isnot particularly attractive. The glass fibers contained within the firstmaterial 40 provide structural reinforcement in when the vehicle doorhandle apparatus 20 is in the final stage of completion. As will beexplained in greater detail below, the glass fibers also reinforce thestructural core 22 when the outer layer 24 is being created by thedisclosed two-shot injection molding process. In accordance with themethod described below, the outer layer 24 is over-molded onto thestructural core 22. The glass fibers in the first material 40 help thestructural core 22 resist deflection when the outer layer 24 is injectedover and fused to the outer surface 32 of the structural core 22 at therequired (atypically high) temperatures.

The outer layer 24 of the vehicle door handle apparatus 20 is made of asecond material 42 that contains the same engineering thermoplastic usedin the first material 40 in addition to a milled material that gives theouter layer 24 a metallic surface finish. Accordingly, it should beappreciated that the second material 42 does not contain glass fibersand is pigmented by the milled material. In accordance with theexemplary configurations described above, the second material 42 may bea pigmented polyox ethylene (POM) when the vehicle door handle apparatus20 is intended to be installed on the interior side of the vehicle doorand the second material 42 may be a pigmented polybutylene terephthalate(PBT) when the vehicle door handle apparatus 20 is intended to beinstalled on the exterior side of the vehicle door. With reference toFIGS. 4 and 5, the milled material comprises micro-flakes 44 thatreflect a large amount of light. In accordance with one aspect of thesubject disclosure, the milled material is aluminum micro-flake and/ormica micro-flake. Each micro-flake 44 of the milled material has adefined geometric shape that may include multiple, substantial planarsurfaces 46 that reflect light. Accordingly, the orientation of themicro-flakes 44 within the outer layer 24 influences the shininess andmetamerism of the metallic surface finish. Generally, the metallicsurface finish will reflect more light (i.e. is more shiny) when a largenumber of the micro-flakes 44 have planar surfaces 46 that are alignedwith (i.e. substantially parallel to) the outer surface 32 of thestructural core 22 (as shown in FIG. 4). The metamerism of the metallicsurface finish (i.e. the uniformity of color matching) and thus theperceived quality of the metallic surface finish is high when a largenumber of the micro-flakes 44 have planar surfaces 46 with similarorientations and when the micro-flakes 44 of the milled material areevenly distributed throughout the outer layer 24 of the vehicle doorhandle apparatus 20 (as shown in FIG. 4). Conversely, the metallicsurface finish of the outer layer 24 may appear cloudy when a largenumber of the micro-flakes 44 have planar surfaces 46 that are notaligned with (i.e. are oblique relative to) one another and the outersurface 32 of the structural core 22 (as shown in FIG. 5). Flow lines,color changes, and other defects may also be visible in the metallicsurface finish of the outer layer 24 when the micro-flakes 44 in thesecond material 42 are not evenly distributed across the outer layer 24(as shown in FIG. 5).

The subject disclosure also includes a method for producing an injectionmolded component having a metallic surface finish, such as the vehicledoor hand apparatus described above. With reference to FIG. 6, themethod comprises a number of steps illustrated by blocks 100 to 112. Themethod includes the step illustrated by block 100 of heating the firstmaterial 40 to a first temperature that is above a melting point of thefirst material 40. In accordance with this step, the first material 40contains the engineering thermoplastic and glass fibers described above.In the example where the first material 40 is a glass reinforcedpolyoxymethylene (POM), the first temperature may be approximately 400degrees Fahrenheit (F). The method includes the step illustrate by block102 of injecting a first shot of the first material 40 into a moldcavity 48 at a first pressure and at a first volumetric flowrate. Asshown in FIG. 7, the process disclosed herein is carried out using amold 50. The mold cavity 48 is disposed within the mold 50 and defines avolume of the injection molded component, which corresponds with thevolume of the vehicle door handle apparatus 20 in the example providedherein. The mold cavity 48 has a surface 52 that is temperaturecontrolled. In accordance with this step, the first volumetric flowrateranges from 33 percent of the volume of the injection molded componentper second to 100 percent of the volume of the injection moldedcomponent per second. In the example where the first material 40 is aglass reinforced polyoxymethylene (POM), the first pressure may rangefrom 8,000 pounds per square inch (psi) to 14,000 pounds per square inch(psi). The method also includes the step illustrated by block 104 ofholding the surface 52 of the mold cavity 48 at a second temperature.The second temperature is below the melting point of the first material40 and is less than the first temperature. This is done in order to coolthe first material 40 that has been injected into the mold cavity 48.During this step, the structural core 22 of the injection moldedcomponent is formed within the mold cavity 48. In the example where thefirst material 40 is a glass reinforced polyoxymethylene (POM), thesecond temperature may range from 55 degrees Fahrenheit (F) to 180degrees Fahrenheit (F).

The method further includes the step illustrated by block 106 of heatingthe second material 42 to a third temperature. The third temperature isabove a melting point of the second material 42, is less than the firsttemperature, and is greater than the second temperature. The secondmaterial 42 contains the engineering thermoplastic and milled materialdescribed above. In the example where the second material 42 is apigmented polyoxymethylene (POM), the third temperature may beapproximately 375 degrees Fahrenheit (F). The method includes the stepillustrated by block 108 of injecting a second shot of the secondmaterial 42 into the mold cavity 48 between the surface 52 of the moldcavity 48 and the structural core 22 at a second pressure and a secondvolumetric flowrate. The second pressure is less than the first pressureand the second volumetric flowrate is less than the first volumetricflowrate. Specifically, the second volumetric flowrate ranges from 5percent of the volume of the injection molded component per second to 25percent of the volume of the injection molded component per second. Inthe example where the second material 42 is a pigmented polyoxymethylene(POM), the second pressure may range from 3,500 pounds per square inch(psi) to 6,500 pounds per square inch (psi). As a result, the secondmaterial 42 is injected into the mold cavity 48 more slowly than thefirst material 40 in order to reduce turbulence in the second shot andthus avoid metameric failure in the second material 42, which ultimatelyforms the outer layer 24 of the injection molded component. Due o theseparameters, the outer layer 24 of the injection molded component has auniform, metallic surface finish with high luster (as shown in FIG. 4)that is free of flow lines and other defects. In other words, themetallic surface finish that is provided is comparable in appearance tothat achieved using a chrome plating process. Conversely, metamericfailure is caused if the distribution and orientation of the milledmaterial in the second material 42 is disrupted or disturbed byturbulence during the injecting step illustrated by block 108. In otherwords, turbulence in the second shot can cause the micro-flakes 44 ofthe milled material to: (1) bunch together and form flow lines in thesecond material 42, and/or (2) change their orientation (i.e. flip andflop) such that the planar surfaces 46 of the micro-flakes 44 arereoriented and are not aligned with one another and the outer surface 32of the structural core 22. FIG. 5 illustrates an example where themetallic surface finish of the outer layer 24 of the injection moldedcomponent is cloudy and has flow line defects because the orientationand distribution of the micro-flakes 44 in the milled material wasdisrupted when the second shot was injected into the mold cavity 48.

Referring again to FIG. 6, the method includes the step illustrated byblock 110 of holding the surface 52 of the mold cavity 48 at a fourthtemperature. The fourth temperature is below the melting point of thesecond material 42, is greater than the second temperature, and is lessthan the third temperature. In accordance with this step, the secondmaterial 42 that has been injected into the mold cavity 48 fuses withthe first material 40 of the structural core 22 to form the outer layer24 around the structural core 22. Because the second shot of the secondmaterial 42 is injected at an atypically slow rate and at an atypicallylow pressure in the step illustrated by block 108 in order to preservethe orientation and distribution of the micro-flakes 44 of the milledmaterial, a much higher mold surface temperature must be used to achieveproper melt flow and ensure that the second material 42 of the outerlayer 24 fuses with the first material 40 of the structural core 22. Inthe example where the second material 42 is a pigmented polyoxymethylene(POM), the third temperature may range from 220 degrees Fahrenheit (F)to 280 degrees Fahrenheit (F). More particularly, the third temperaturemay be approximately 245 degrees Fahrenheit (F). It should also beappreciated that the glass fibers in the first material 40 help keep thestructural core 22 of the injection molded component from deflecting asthe second shot flows around and fuses to the structural core 22 atthese atypically high mold temperatures. In the absence of the glassfibers, the nominal thickness 38 of the outer layer 24 would bedifficult to control and would vary considerably across the outersurface 32 of the structural core 22. Such deflection and variance inthe nominal thickness 38 could also promote metameric failure in themetallic surface finish of the outer layer 24.

The method continues with the step illustrated by block 112 of removingthe injection molded component from the mold cavity 46 to cool theinjection molded component further. In accordance with this step, theinjection molded component may be allowed to cool to room temperature,for example. It should be appreciated that by the time this step isperformed, the injection molded component includes both the structuralcore 22 and the outer layer 24 and thus may be in its final stage ofcompletion. The injecting steps of the method illustrated by blocks 102and 108 may be configured to give the outer layer 24 of the injectionmolded component a desired thickness. For example, the volume of thefirst material 40 that is injected into the mold cavity 48 may be isless than the volume of the mold cavity 48 by a predetermined value suchthat the volume difference created by the predetermined value produces aspace between the surface of the mold cavity 48 and outer surface 32 ofthe structural core 22. The second material 42 flows into and occupiesthis space when the outer layer 24 is formed. By controlling the volumedifference between the volume of the first material 40 that is injectedinto the mold cavity 48 and the volume of the mold cavity 48, thenominal thickness 38 of the outer layer 24 can be controlled. Inaccordance with the examples described herein, the nominal thickness 38of the outer layer 24 may be selected to range from 0.5 millimeters (mm)to 3.0 millimeters (mm).

Although the various temperatures and pressures disclosed herein inconnection with the process for manufacturing the injection moldedcomponent relate to the example where the first material 40 is a glassreinforced polyoxymethylene (POM) and the second material 42 is apigmented polyoxymethylene (POM) that does not contain glass fibers, theprocess is not limited to such materials. It should be understood thatthe process may be adapted for use with other engineering thermoplasticsuch as where the first material 40 is a glass reinforced polybutyleneterephthalate (PBT) and the second material 42 is a pigmentedpolybutylene terephthalate (PBT) that does not contain glass fibers, forexample. Similarly, the milled material may be aluminum micro-flake,mica micro-flake, or other suitable alternatives. With regard to thetemperatures recited in the disclosed process, the term “approximately”means within plus or minus 10 percent (%) of the stated temperaturevalue. It should be understood that the order of the method stepsillustrated and described herein is not intended to be limiting. Unlessotherwise noted, the steps of the method may be performed concurrentlywith one another or in a different sequence than that presented. Itshould also be understood that the process set forth herein may beperformed along with or in addition to other method steps that are notdescribed or illustrated without departing from the scope of the presentdisclosure.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.These antecedent recitations should be interpreted to cover anycombination in which the inventive novelty exercises its utility. Manymodifications and variations of the present invention are possible inlight of the above teachings and may be practiced otherwise than asspecifically described while within the scope of the appended claims.

What is claimed is:
 1. A vehicle door handle apparatus comprising: astructural core including a base portion with at least one mountingfeature and a handle portion that extends from said base portion; saidstructural core having an outer surface that extends along said baseportion and said handle portion; an outer layer extending about andcovering said outer surface of at least said handle portion of saidstructural core; said structural core being made of a first materialthat contains an engineering thermoplastic and glass fibers forreinforcement; and said outer layer being made of a second material thatcontains said engineering thermoplastic and a milled material to givesaid outer layer a metallic surface finish.
 2. The vehicle door handleapparatus as set forth in claim 1 wherein said first material is a glassreinforced polyoxymethylene and said second material is a pigmentedpolyoxymethylene.
 3. The vehicle door handle apparatus as set forth inclaim 1 wherein said first material is a glass reinforced polybutyleneterephthalate and said second material is a pigmented polybutyleneterephthalate.
 4. The vehicle door handle apparatus as set forth inclaim 1 wherein said second material does not contain glass fibers. 5.The vehicle door handle apparatus as set forth in claim 1 wherein saidmilled material is selected from a group consisting of: aluminummicro-flake and mica micro-flake.
 6. The vehicle door handle apparatusas set forth in claim 1 wherein said outer layer has a nominal thicknessranging from 0.5 millimeters to 3 millimeters.
 7. The vehicle doorhandle apparatus as set forth in claim 1 wherein said outer layer isovermolded onto said structural core by a two-shot injection moldingprocess.
 8. The vehicle door handle apparatus as set forth in claim 1wherein said outer surface of said structural core has a dull surfacefinish.
 9. The vehicle door handle apparatus as set forth in claim 1wherein said outer surface includes a front face and a rear face that isoppositely directed with respect to said front face and wherein saidouter layer covers both said front face and said rear face of said outersurface at said handle portion.